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Process Improvement


up to 500-mm long. “With this machine we are rounding out our range of crankshaſt grinders to include the machining of smaller components,“ said Guido Hegener, managing director of EMAG Maschinenfabrik GmbH (Neu-Isenburg, Germany). “Up to now, our range of machines did not include a horizon- tal twin-head grinder for smaller crankshaſts. Tis gap is now filled with the PMD 2, a machine with a price/performance ratio suited to combat the increasing competition in the auto- motive industry.” Te basis for the PMD 2 is the established Series 2 from


EMAG Naxos-Union and EMAG Kopp. Tese machines combine high-tech grinding technology with precision, ef- ficiency, process integrity and simple operation. Tis applies to the PMD 2 as well, where two CBN grinding wheels machine crankshaſts to a high level of precision. To achieve this, the machine is equipped with a direct-driven workspindle, hydro- static guideways and a linear motor in the X-axis, as well as an in-process measuring control that allows for roundness moni- toring and correction in the machine. “Te operator enters the relevant command in the control and the measuring process is carried out once the bearing has been ground. Te soſtware, developed by EMAG, then calculates the relevant correction values from the remaining roundness errors. Tis allows for the subsequent manufacturing processes to be successively optimized,” added Hegener. Te technology also stands out with its simultaneous use


The PMD 2 crankshaft grinder is compact and flexible with readily accessible components.


EMAG LLC (Farmington Hills, MI) offers precision solu-


tions to address this situation. One solution, for example, ap- plies to crankshaſts, where a lot is dependent on the grinding process carried out on this core engine component. In the fu- ture, the process must be of greater precision and subject to an even higher degree of efficiency. EMAG has worked to achieve that efficiency in its PMD 2 crankshaſt grinder. Tis machine incorporates EMAG Naxos-Union technology and provides high output rates with a notable price/performance ratio. A crankshaſt is not only a component that is subject to the


industry’s cost-cutting pressure, but also one upon which the engine depends for efficiency and stability. Tus, a work- intensive grinding operation in the micrometer range is required. EMAG has the capability to develop tailor-made grind-


ing solutions for shaſt-type components. Te new PMD 2 machine complements this crankshaſt grinder know-how. It is designed for the machining of passenger car crankshaſts and features twin grinding heads that allow the simultaneous grinding of two pin or main bearings in a single setup using two grinding wheels. Its capacity covers small components


80 Motorized Vehicle Manufacturing


of two grinding wheels. Te twin-tool process opens up a number of possibilities for the user, depending on component and machining requirements. Two pin bearings or main and pin bearing are machined simultaneously, reducing cycle times. For instance, a four-cylinder crankshaſt is machined in less than two minutes. Te grinding wheels can, if required, be arranged very close together so that adjoining pin and main bearings can be machined simultaneously. Both grinding spin- dles and work headstock are direct-driven, further increasing precision and productivity levels. “We have strung together a technologically very interesting package,” stated Hegener. Te machine is also compact and constructed to allow


flexibility. For example the electrical cabinet is included in the enclosure. Connecting an automatic loading system poses no problem, and both emulsion and oil can be used as coolants. “Flexibility was of great importance in using this technol-


ogy,” said Hegener. “We tailor the machine exactly to the customer’s requirements. Integration into an existing, complex production line is an important option, but there is the option of the machine being used as a stand-alone solution with manual loading. We expect this approach will give users a competitive edge while component quality and production costs are gaining importance world-wide.”


Edited by Yearbook Editor James D. Sawyer from information provided by EMAG LLC.


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